Metal working fluids



United States Patent 3,202,607 METAL WORKING FLUIDS John E. Koch, .ln, Bayonne, NJ, assignor to Celanese Corporation of America, New York, N.Y., a corporation of Delaware N0 Drawing. Filed Dec. 21, 1961, Ser. No. 161,254 Claims. (Cl. 252-49.5)

This invention relates to functional fluids for metal Working for example cutting, grinding, rolling, drawing, blanking, broaching, slotting, milling, threading, drilling, etc. It more particularly refers to fluids particularly well suited for use as aqueous dispersions in the working of extremely hard alloys and steels as well as brass, copper and other non ferrous metals and alloys.

Metal working fluids have been known for many years. Conventional petroleum-base oils are generally adequate for use in Working metals of a conventional nature. However, when employed in the working of the newer special steels and alloys of extreme toughness and/or hardness, as for example: nickel, iron, chromium, molybdenum, titanium alloys such as lncoloy 901; nickel, copper alloys such as Monel; nickel, chromium, molybdenum alloys such as Waspaloy; iron, nickel alloys such as A.M.S. 56- 60; stainless steels (iron, carbon, chromium alloys) such as A.I.S.l. D2; 80-20 and 7030 brass; pure copper; and cupro nickel (A.S.T.M. Bl1l), petroleum-base fluids have been known to promote dermatitis and present fire hazards. Additionally, straining and high internal stresses have been noted in the metal when it is worked using petroleum based cutting or grinding fluids. It is thought that the straining and high internal stress are due to insuflicient heat dissipation by the cutting or grinding oil which results in excessive heat build-up in the metal.

The problem of adequate heat dissipation with respect to many metals has been alleviated by the use of waterbased glycol-type cutting and grinding fluids. It has been found, however, that most water-base fluids now commercially available cause excessive grinding-wheel wear and therefore using water base grinding fluids has been relatively uneconomical.

It is, therefore, an object of this invention to provide novel functional fluids. It is another object of this invention to provide novel functional fluids for use in Working very hard metals. It is a further object of this invention to provide novel functional fluids which do not suffer from the disadvantages set forth above. It is a still further ob ject of this invention to provide novel functional fluids which are relatively economical to use in the cutting or grinding of relatively hard metals. Other objects of this invention will become apparent from the following detailed description of this invention and from the claims.

In accor with these objects, this invention includes the working of metals with the aid of a fluid comprising polyoxyethylene adduct of castor oil, water soluble glycol and water. This invention is particularly applicable to the working of the very hard metals, such as for example those set forth above. Further, this invention is of particular value where the metal working operation mentioned above is carried out through the use of such tools as carbide tipped cutting tools, diamond abrasive Wheels and hard steeltools.

This invention also includes the novel fluids which are useful as metal working aids. Such fluids comprise a non-aqueous fluid portion dispersed in water. Nonaqueous fluids for use in this invention suitably contain one or more polyoxyethylene adducts of castor oil; at least one glycol, which can be dipropylene glycol, propylene glycol, 1,3-butylene glycol and/ or hexylene glycol; and various additive materials. In accord with this in vention, propylene glycol and dipropylene glycol are interchangeable materials. That is these materials can be used in the proportions set forth below, which proportions can consist entirely of one or the other, or a combination of the two propylene and dipropylene glycol. It is within the spirit and scope of this invention to utilize either propylene glycol, dipropylene glycol or both with or without hexylene glycol.

Thus in the embodiment of this invention wherein the non-aqueous fluid described above consists of either propylene glycol or dipropylene glycol and at least one polyoxyethylene adduct of castor oil as well as the additives referred to above, the glycol or mixture thereof is suitably present in a proportion from about to 80 weight perabove as an extreme pressure additive.

cent of the fluid, the polyoxyethylene adduct of castor oil or mixtures thereof suitably represents about 10ft0 60 Weight percent of the fluid, and the additives suitably represent about 5 to 15 weight percent of the fluid. Preferred ranges of proportions are: glycol 40 to 75 weight percent; polyoxyethylene adduct of castor oil 15 to 35 weight percent and additives 8 to 12 percent.

In the embodiment of this invention which utilizes hexylene glycol in combination with propylene glycol, dipropylene glycol or a combination thereof, it is convenient to provide a fluid comprising about 5 to weight percent hexylene glycol, about to 65 weight percent propylene glycoLdipropylene glycol or a mixture thereof, about 10 to Weightpercent polyoxyethylene adduct of castor oil or mixtures thereof, and about 5 to 15 weight percent additives. In this latter embodiment it is preferred to use 15 to 20 weight percent hexylene glycol, 40 to weight percent propylene glycol; dipropylene glycol or a mixture thereof, 15 to 35 weight percent polyoxyethylene adduct of castor oil or mixtures thereof, and 8 to 12 weight percent additives.

It has been found in the practice of this invention that the optimum concentration of glycol for cutting metal working operations is 55 to 65 Weight percent and that the optimum concentration of glycol for rolling metal working operations is 50 to weight percent. 7

Polyoxyethylene adducts for castor oil Which have been found to be useful in this invention contain from about 10 to 80 percent combined ethylene oxide, preferably 18 .to percent combined ethylene oxide. Various adducts stat agents, or the like, inproportions conventionally' used for the intended purpose. In particular, it has been found effective to utilize a tertiary nonyl polysulfide (marketed as TNPS by the Pennsalt Chemical Company), or dibenzyl disulfide in a proportion up to about 5 weight percent of the non-aqueous mixture setforth It has also been found that petroleum sulfonate (marketed by Sonnenborn Co. as Petromix 9B) in a proportion of up to about 5 weight percent of the non-aqueous mixture set forth above, is an excellent emulsifier. Proportions of up to about 2% of ethylidene diacetate or phenyl mercuric acetate have been found to be excellent bacteriostats. It should be understood that the use of ethylidene diacetate as a bacteriostat is the subject of a separate application for patent to be filed subsequently. Polyoxyethylene octadecyl amine (up to about'5%) has been found to be a good rust and stain inhibitor. 'It is within the: scope of thisinvention to use any, all or none ofthese additives as the particular metal Working operation requires.

The non-aqueous mixtures set forth above'is. conveniently mixed with a desired amount of water to provide a metal working fluid. Ratios of water to the non- EXAMPLE I A grinding fluid was prepared having the following constituents:

The grinding fluid was prepared by mixing together the two polyoxyethylene adducts of castor oil and the dipropylene glycol and then forming an emulsion of this non-aqueous mixture in water.

The non-aqueous portion of the grinding fluid was a liquid having a viscosity of 74 cs. The viscosity of the final emulsion was almost that of water.

EXAMPLE II A grinding fluid was prepared as in Example I, utilizing as constituents of the non-aqueous mixture:

18 parts by weight polyoxyethylene adduct of castor oil having a specific gravity of 0.98 to 0.985, a viscosity of 305 cs., an hydroxyl value of 145 to 150 and 18 a percent combined ethylene oxide;

18 parts by weightpolyoxyethylene adduct of .castor oil having 40% combined ethylene oxide asdescribed in 3 Example I;

-5 parts by weight tertiary nonyl polysulfide;

5 parts by weightpetroleum sulphonate;

54 parts by weight dipropylene glycol;

0.02 part by weight of dye; and

0.15 part by weight masking agent.

EXAMPLE III A metal working fluid was prepared by mixing together (all proportions are by weight):

12.5 parts of polyoxyethylene adduct of castor oil having 18% combined ethylene oxide as set forth in Example II;

12.5 parts of polyoxyethylene adduct of castoroil having 40% combined ethylene oxide as 'set forth in Example I;

20 parts hexylene glycol;

44.83 parts dipropylene glycol;

5 parts petroleum sulphonate;

.2 parts dibenzyl disulfide; .2 parts polyoxyethylene octadecyl amine;

1 part 18% solution of phenyl mercuric acetate; and 600 parts by weight of water.

The non-aqueous portion of the metal working fluid .was a liquid having a viscosity of 59.2 cs. viscosity at 100 F. The emulsion had a viscosity almost equalto that of water.

Grinding fluids made according to this inventionhave heen tested to determine their lubricity. The results of tests on the fluids of the above specific examples ap- :pear.in Table'I, below. With respect to these test data,

the Shell 4-bal1wear test procedure is set forthin the Lubrication EngineersrManual put out by the U.S. Steel Corporation at page DM53.

The referred to Falex test procedure is set forth in the same reference on page DM58.

:1, TABLE I Shell Test Falex Test Example Emulsion Ratio 1 1 kg. 40 kg. J aw Load, Torque,

pounds lb.-in.

I 1:1. 5 0. 40 0.65 4, 500 48 1:15 0.37 0. 65 4, 500 II 1:6 0.48 0. 99 4, 500 42 1:15 0. 50 0.85 4, 500 40 III 1:6 0. 25 0. 90 4, 500 40 1:15 0.30 0. 90 4, 500 43 1 Non-aqueous mixture to water.

By way of comparison, conventional petroleum grind ing oils when subjected to the Falex test at a jaw load of greater than 4500 pounds showed very high torques of 77 and 80 pound-inches, and a conventional waterbase grinding fluid showed a torque of 62 pound-inches under a 4500 pound jaw load. Thus it should be noted that the instant invention is a marked improvement over conventional grinding or cutting fluids.

In order to further test the properties of the metal working fluids of this invention, various exemplary fluids were used in industrial metal working operations. In a grinding application, an iron-nickel alloy, AMS 56-60, was subjected to the action of a grinding wheel set to remove a 1% inch wide and 0.0025 inch deep section of metal. In utilizing 45 amperes and having 0.0022 inch of the grinding wheel diameter removed in the operation, a metal section of the desired width and 0.00205 inch deep was removed using the composition set forth in Example I as the grinding fluid. In another test on lathe turning of a stainless steel, A.I.S.I. D-2, it was possible through the use of a cutting fluid as set forth in Example III to remove 0.003 inch of metal in one cut with a good finish on the cut piece.

Although this invention has been described with particular reference to the use of polyoxyethylene adducts of castor oil, it will be understood that other similar materials are also useful in this invention such as for example: polyoxypropylene adducts of castor oil; mixed polyoxyethylene and polyoxypropylene adducts of castor oil; ;polyoxy lower alkylene adducts of glycerides of hydroxy fatty acids such as adducts of ethers of hydrogenated castor oil.

It is to be understood that the foregoing detailed description is given merely by way of illustration and that many variations may be made therein without departing from the spirit of my invention.

Having described my invention, what I desire to secure by Ietters'Patent is:

1. A non-aqueous fluid mixture adapted to use in aqueous metal working compositions comprising about 20 to 80 weight percent of at least one member selected from the group consisting of propylene glycol and dipropylene glycol; and about 10 to 60 weight percent of/a polyoxyethylene adduct of castor oil having 18-65 weight percent combined ethylene oxide.

2. A fluid mixture as claimed in claim 1 having 40 to 75 weight percent glycol, 15 to 35 weight percent polyoxyethylene adduct of castor oil, and 8 to 12 weight percent additives.

3. A non-aqueous fluid mixture adapted to use in aqueousmetal working compositions comprising about 5 to 30 weight percent hexylene glycol, about 35 to weightpercent of a glycol selectedfrom the group consisting of propylene glycol and dipropylene glycol, and .about 10m 45 weight percent of a polyoxyethylene adduct of castor oil having '18-65 weight percent combined ethylene-oxide.

,4. A fluid as claimed in claim 3 having 15 to 20 weight percent hexylene glycol, 40 to 55 weight percent of at least one glycol selected from the group consisting of propylene glycol and dipropylene glycol, 15 to 35 weight percent polyoxyethylene adduct of castor oil, 1,3 butylene glycol and 8 to 12 weight percent additive.

5. A metal working fluid comprising about 1 to 200 parts by weight water per part of non-aqueous fluid mixture claimed in claim 1.

6. A fluid claimed in claim 5 having about 3 to 40 parts by weight of water.

7. A metal working fluid comprising about 1 to 200 parts by weight of water per part of non-aqueous fluid mixture claimed in claim 3.

8. A grinding fluid consisting essentially of about:

7.5 parts by weight of a polyoxyetheylene adduct of castor oil having about 40% combined ethylene oxide;

42.5 parts by weight of a polyoxyethylene adduct of castor oil having about 65% combined ethylene oxide;

50 parts by weight dipropylene glycol; and

150 parts by weight water.

9. A grinding fluid consisting essentially of about:

18 parts by weight of a polyoxyethylene adduct of castor oil having about 18% combined ethylene oxide;

18 parts by Weight of a polyoxyethylene adduct of castor oil having about 40% combined ethylene oxide; a

5 parts by weight of tertiary nonylpolysulfide;

5 parts by weight of petroleum sulphonate;

54 parts by weight dipropylene glycol; and

150 parts by weight of water.

10. A metal working fluid consisting essentially of about:

12.5 parts by weight of a polyoxyethylene adduct of castor oil having about 18% combined ethylene oxide;

12.5 parts by weight of a polyoxyethylene adduct of castor oil having about 40% combined ethylene oxide;

20 parts by weight hexylene glycol;

parts by weight of dipropylene glycol;

5 parts by Weight of petroleum sulphonate;

2 parts by weight of dibenzyl disulfide;

2 parts by weight polyoxyethylene octadecylamine;

1 part by weight of about 18% aqueous solution of phenyl mercuric acetate; and

600 parts of water.

References Cited by the Examiner UNITED STATES PATENTS 2,563,588 8/51 Dixon 25249.5 X 2,914,477 11/59 Cafcas et al 25249.5 X 2,948,681 8/60 Milberger et al 25249.5 X 2,968,621 1/61 Tieter et a1. 25249.5 X 3,024,198 3/62 Harrington et a1 25249.5 X

DANIEL E. WYMAN, Primary Examiner.

JULIUS GREENWALD, Examiner. 

1. A NON-AQUEOUS FLUID MIXTURE ADAPTED TO USE IN AQUEOUS METAL WORKING COMPOSITIONS COMPRISING ABOUT 20 TO 80 WEIGHT PERCENT OF AT LEAST ONE MEMBER SELECTED FROM THE GROUP CONSISTING OF PROPYLENE GLYCOL AND IPROPYLENE GLYCOL; AND ABOUT 10 TO 60 WEIGHT PERCENT OF A POLYOXYETHYLENE ADDUCT OF CASTOR OIL HAVING 18-65 WEIGHT PERCENT COMBINED ETHYLENE OXIDE.
 5. A METHAL WORKING FLUID COMPRISING ABOUT 1 TO 200 PARTS BY WEIGHT WATER PER PART OF NON-AUQUEOUS FLUID MIXTURE CLAIMED IN CLAIM
 1. 